Abstract: Amorphous polyamide terpolymers with a high level of transparency, transition glass temperature, flexibility, and chemical resistance. In one embodiment, the polyamide terpolymers are polymerized from caprolactam, at least one diamine, and at least one diacid.

Abstract: The disclosure relates generally to a synthetic agricultural product and methods and systems for producing a synthetic agricultural product or composition. The method of producing a synthetic agricultural product may comprise providing an effective amount of fertilizer and/or other agricultural product sufficient to effectuate a response in a plant, an effective amount of a mineral substance having a high cation exchange capacity, and an effective amount of water sufficient to effectuate a desired result in a plant. The fertilizer and/or other agricultural product and mineral substance may be added into the effective amount of water, thereby creating the synthetic agricultural product. Known ions, such as fertilizer ions, and native ions in the native mineral substance may be exchanged to produce a synthetic agricultural product.

Abstract: Methods of using a clay stabilizing agent to inhibit swelling and/or migration of clay subterranean materials upon exposure to water, wherein the clay stabilizing agent is selected from quaternary ammonium salts according to Formula I, Formula II, Formula III, Formula IV, Formula V, and combinations thereof.

Abstract: The invention is directed to a method for fabricating a mesoporous carbon composite material. The method comprises providing a precursor composition and subjecting the precursor material to a curing step followed by carbonization step. The precursor composition comprises (i) a templating component comprised of a linear homopolymer material, (ii) a phenolic compound or material, (iii) a crosslinkable aldehyde component, and (iv) an acid catalyst.

Abstract: A method of inhibiting scale in a subterranean formation comprises pretreating the subterranean formation with a polyquaternary amine that serves as a squeeze life extension (SLE) agent, and then introducing a scale inhibitor pill into the subterranean formation, wherein the scale inhibitor pill includes one or more scale inhibitor compositions. For example, the polyquaternary amine may be a polymer having up to 5 quaternary amine centers, but is preferably a nonpolymeric diquaternary amine having a molecular weight of from 250 to 500. One such example is 1,3-propandiaminium, 2-hydroxy-N,N,N,N?,N?,N?-hexamethyl-, dichloride. The SLE agent is preferably introduced into the formation in a brine solution having a concentration from 0.1 to 20 weight percent. The SLE agents may be used with a variety of known scale inhibitors and scale inhibitor chemistries.

Abstract: The invention provides a ceramic green sheet having plasticity, punching property, and sinterability of satisfactory levels as well as a low percent (heat) shrinkage. In the production of a ceramic slurry serving as a raw material of the sheet, ingredients thereof are mixed under such conditions that the functional group ratio (polyol to isocyanate) is 1.5/11.5 to 11.5/11.5; the urethane resin formed from isocyanate and polyol has a repeating-unit-based molecular weight of 290 to 988; and the ratio by weight of the urethane resin to a ceramic powder falls within a range of 4.5 to 10 parts by weight of the urethane resin with respect to 100 parts by weight of the ceramic powder. A ceramic green sheet having, in well balance, all of the properties (i.e., plasticity, punching property, sinterability, and (heat) shrinkage) required for facilitating subsequent processes such as mechanical working and firing can be provided.

Abstract: Disclosed herein are methods for removing discoloring impurities, such as carbon impurities, particularly graphite, from kaolin clay to enhance the brightness of the kaolin clays. The methods include reverse flotation processes. Also disclosed herein are high brightness kaolin products, and the uses thereof.

Abstract: nuc-PP nanocomposite is made from the mixing of nuc-PP with olefin elastomer and organoclay, and optionally, a dispersion agent. Unexpectedly, processing properties such as higher melt flow, and performance properties such as higher toughness and higher stiffness, are obtained when compared with commercially available PP nanocomposite.

Abstract: A layered silicate characterized by being ion-exchanged with an organic onium ion at 50-100% of its ion-exchange capacity, and by having a specific surface area of 2.5-100 m2/g, as well as a resin composition comprising a thermoplastic resin and the aforementioned layered silicate, the resin composition being characterized in that the layered silicate content is 0.01-20 parts by weight as inorganic ash with respect to 100 parts by weight of the thermoplastic resin, and the average number of layers of the layered silicate in the thermoplastic resin is 2-8 layers. Also, a film which comprises the resin composition.

Abstract: A method of use of polyaminomethylenephosphonates as dispersing, wetting, and/or stabilizing agents in formulations for cements, detergents, ceramic materials, dyes, synthetic resins, rubbers, drilling fluids, and for reverse osmosis includes the step of adding a polyaminomethylenephosphonate having the formula: wherein n is an integer higher than 2, M is an alkaline metal or the ammonium ion, and R is: —CH2PO3M2; —CH2Z, wherein Z is —CH2OH, —CHOHCH3, —CHOHCH2Cl, or —CHOHCH2OH; —(CH2)mSO3M, m being 3 or 4; —CH2CH2T, wherein T is —CONH2, —CONH2, —CHO, —COOQ, —COOX, CN, wherein Q is —CH3 or —C2H5 and X is an alkaline metal ion or the ammonium ion; and wherein the polyaminomethylenephosphonate is present in a weight quantity of over 0.01% with respect to the total weight of the formulation.

Abstract: The present invention relates to coarse calcined kaolin slurries having a high solids content. The invention also relates to methods of making such slurries. The resulting slurries can have a solids content of at least about 58% by weight wherein at least about 40% by weight of the calcined kaolin particles has a particle size of at least about 1 ?m. The slurries can be stabilized where the solids show little settling from suspension. The slurries have many uses, including fillers or extenders in paint and coating compositions for paper or paper board. More generally, the inventive products may be used wherever calcined kaolins are used. The present invention also related to coarse calcined kaolin slurries having a multimodal particle size distribution and a high solids content.

Abstract: An improvement in a mixture for forming into a body that is to be fired into a “whiteware ceramic product” wherein the mixture is a compound of clay and other minerals with a ferric oxide content of less than about 5.0% by weight of the dry mixture. The improvement includes adding to the mixture a binder in the form of a combination of protein and a vegetable flour with an equivalent gram strength of at least 30 grams and a protein content of 20-50% of the binder, where the binder is in the range of 0.05% to 0.50% by weight of the dry mixture.

Abstract: Intercalates and exfoliates formed from layered materials and dendritic polymers are disclosed, together with the uses of these materials, e.g. in producing composite materials. The dispersion of layered materials in a dendritic polymer matrix (hyperbranched polymers, star shaped polymers or star branched polymers) or has not been disclosed in the prior art. The high number of end-groups per molecule of dendritic polymer combined with their unique globular architectures leads to large intergallery spacings when intercalated in layered silicates and particularly facile exfoliation in spite of the high molar mass of the dendritic polymer. The excellent processability and potential high reactivity of dendritic polymers makes them extremely promising for thermoset applications, and coatings.

Abstract: The present invention relates to a splayed material comprising a layered material splayed with a particle having a diameter equal to or less than 3 micrometers. Another embodiment of the invention includes an article comprising a matrix and a layered material splayed with a polymeric particles dispersed in a medium. The invention also relates to methods for preparing these materials via mixing, milling and emulsifying a solvent borne polymer with a surfactant. A further method describes a method for preparing a nanocomposite from a splayant particle prepared by combining an emulsion polymerization monomer and a surfactant dispersible in a medium wherein the monomer is not dispersible in the medium.

Abstract: The invention relates to polymer modified inorganic particles with a layer structure with an average particle diameter of 5 nm to 20,000 nm, containing 20 to 5000 mass % interlamellarly, in relation to the anhydrous inorganic particle, of a mixture of aminoplasts and water. These polymer modified inorganic particles are produced by swelling the inorganic particles with aldehydes and then reacting the inorganic particles with multifunctional C1–C30 amino compounds. The invention also relates to plastic containing polymer modified particles with a layer structure and to semi-finished products and moulded material produced from the same.

Abstract: Polymer-phyllosilicate nanocomposites that exhibit superior properties compared to the polymer alone, and methods-for producing these polymer-phyllosilicate nanocomposites, are provided. Polymeric surfactant compatabilizers are adsorbed onto the surface of hydrophilic or natural phyllosilicates to facilitate the dispersal and exfoliation of the phyllosilicate in a polymer matrix. Utilizing polymeric glycol based surfactants, polymeric dicarboxylic acids, polymeric diammonium surfactants, and polymeric diamine surfactants as compatabilizers facilitates natural phyllosilicate and hydrophilic organoclay dispersal in a polymer matrix to produce nanocomposites.

Abstract: The present invention provides an improved method of beneficiating and dewatering kaolin clays. The product of the improved process is a brightened, dewatered kaolin, suitable for use in pigments and paper coating compositions. The improved beneficiation process provides refined kaolin for pigments and other purposes of the same or better quality as prior art processes, but with the use of fewer steps and materials, at significant cost and environmental savings.

Abstract: Processes for modifying the surface chemistry of a clay are disclosed. In one embodiment, there is provided a process for modifying the surface chemistry of a clay, wherein the process comprises: providing a clay dispersion comprising at least one unmodified clay wherein said clay has a first exchangeable cation; adding a second cation to the clay dispersion, wherein at least a portion of the second cation exchanges with at least a portion of the first cation to form a modified clay dispersion; and combining at least one polar containing agent with the modified clay dispersion to provide a modified clay.

Abstract: The invention provides nanocomposites comprising a clay and an organic compound, in which the clay is a clay bridged by a metal compound, preferably iron oxide and/or aluminum oxide. The organic compound is preferably a polymer. The clay-based nanocomposites of the invention have good mechanical properties and good heat resistance. The invention also provides cables comprising such a nanocomposite, preferably in their sheath or outer coating. Finally, the invention provides a process for producing said nanocomposite.

Abstract: The invention relates to a porous mold for use in a pressure casting process, which mold is manufactured of a polymeric material forming a matrix into which a clay and a block copolymer or a graft copolymer have been incorporated, wherein the block copolymer or graft copolymer comprises one or more first structural units (A), which are compatible with the clay, and one or more second structural units (B), which are compatible with the polymeric matrix. The invention further relates to a process for producing said mold and to the use of said mold in a pressure casting process.

Abstract: This invention relates to a process for producing a free radical control agent of the structural formula: wherein Z is selected from the group consisting of wherein R1 is an alkyl group of 1 to 4 carbon atoms, cyclohexyl or phenyl; wherein R2 is an alkoxy group of 1 to 8 carbon atoms or a cycloalkoxy group of 5 to 8 carbon atoms; wherein Alk is a divalent hydrocarbon of 1 to 18 carbon atoms; and wherein Y represents a functional group that is capable of activating a vinylic carbon toward free radical addition; said process comprising the steps of (1) reacting a mercaptosilane of the structural formula: Z-Alk-SH with carbon disulfide in the presence of a phase transfer catalyst and an alkali metal hydroxide to produce a trithiocarbonate salt; and (2) reacting the trithiocarbonate salt with a halogen containing compound of the structural formula X-Y to produce the free radical control agent, wherein X represents a halogen atom.

Abstract: A method of dewatering an aqueous mineral suspension comprising introducing into the suspension a flocculating system comprising, a) a substantially non-ionic polymeric flocculant and b) an anionic polymeric flocculant, characterised in that, the substantially non-ionic polymeric flocculant is added to the suspension before the addition of the anionic polymeric flocculant. The method is useful for flocculating China clay suspensions, suspensions of s welling clays, calcium carbonate suspensions, titanium dioxide suspensions, suspensions of coal tailings, red mud and phosphate slimes etc.

Abstract: This invention relates to preparation and use of nanocomposites formed in situ within an elastomer host wherein the nanocomposite is comprised of an elastomer matrix and a dispersion therein of at least partially exfoliated clay platelets. Rubber composites can be prepared by blending such nanocomposite with additional elastomer(s), additional reinforcing filler(s) and/or a coupling agent. The invention further relates to the preparation of articles of manufacture, including tires, having at least one component comprised of said nanocomposite or said rubber composite. Such a tire component may be selected from, for example, tire tread and tire innerliner.

Abstract: Nanocomposites may be produced by mixing dispersions of polymers and dispersions of clay minerals. After mixing, the dispersions may be destabilized with the addition of appropriate compounds. The flocculated solid material exhibits characteristics of a nanocomposite, such as exfoliation of the clay mineral platelets as indicated by x-ray diffraction analysis.

Abstract: Co-Ion exchange of the interlayer cations of a layered silicate with a mono-protonated aromatic diamine and an alkyl ammonium ion into the silicate galleries. The presence of the alkyl ammonium ion provides low oligomer melt viscosity during processing. The presence of the diamine allows chemical reaction between the silicate surface modification and the monomers. This reaction strengthens the polymer silicate interface, and ensures irreversible separation of the individual silicate layers. Improved polymer thermal oxidative stability and mechanical properties are obtained.

Abstract: A method for preparing organoclays for use as rheological control agents and in the preparation of nanocomposites. Typically, the clay is dispersed in water, and a specific amount of polymeric hydrotrope, ranging from 0.1 to 15 weight percent relative to the weight of the clay, is adsorbed onto the clay surface. Quaternary amine exchange is also performed on the clay to modify the surface hydrophilic/lipophilic balance (HLB) of the clay.

Abstract: Disclosed is a method for preparing a clay-dispersed polymer nanocomposite. In this method, a polymer, which carries oxygen atoms within the repeating units of its backbone and is thermodynamically compatible with a binder resin, is used as a matrix resin. Useful is poly(&egr;-caprolactone) owing to its thermodynamic compatibility with poly(styrene-co-acrylonitrile)copolymers, poly(acrylonitrile-co-butadiene-co-styrene) copolymers, and poly(vinylchloride) resins. Poly(&egr;-caprolactone) resins aid the binder resins to penetrate into silicate layers so that the silicate of the organophilic clay was completely delaminated to silicate lamellas.

Abstract: An intercalated clay comprising a clay intercalated with a block copolymer wherein said block copolymer comprises a hydrophilic block capable of intercalating said clay. An additional embodiment is an article comprising a matrix polymer and clay wherein said clay is intercalated with a block copolymer, wherein said block copolymer comprises a hydrophilic block capable of intercalating said clay and a matrix compatible block compatible with said matrix polymer.

Abstract: The present invention discloses a complex of clay and polyoxyalkylene amine and a method for producing the same. The clay in the present invention is layered and includes silicate, and the polyoxyalkylene amine with molecular weight over 1,800 is provided as an intercalacting agent to enlarge interlayer distances of the clay at an unprecedented spacing. The method for producing the complex is primarily to acidify the polyoxyalkylene amine with an inorganic acid, which is then mixed with the clay swelled with water previously; and the mixture is then powerfully stirred at 60-80° C. for cation exchanging to obtain the titled inorganic/organic complex. According to the present invention, the complex is an excellent surfactant and a reinforcing agent of polymers.

Abstract: The invention is directed to a polymer-clay nanocomposite material comprising a melt-processible matrix polymer and a layered clay material having low quartz content. This invention is also directed to a process for preparing polymer-clay nanocomposites, and articles or products produced from nanocomposite materials.

Abstract: A process for preparing a ball clay slurry with a casting rate of at least about 50, a modulus of rupture of at least 500 pounds per square inch, and from about 0.1 to about 1.0 weight percent of organic polyelectrolyte. In this process, a digested lignite material is mixed with a lignitic coarse clay, a nonlignitic coarse clay, a lignitic fine clay, and a polyelectrolyte dispersing agent.

Abstract: A clay slurry is described using smectite clay, water, and a defined phosphonate additive that is hydrolytically stable over time. The viscosity of the clay slurry remains pourable and relatively unchanged over time compared to prior art slurries. The slurry is useful to provide rheological control to paints and coatings and is particularly useful as an anti-bleed additive for concrete.

Abstract: The invention is directed to a polymer-clay nanocomposite material comprising a melt-processible matrix polymer and a layered clay material having decreased levels of extractable material, such as extractable salts of organic cations. This invention is also directed to processes for preparing polymer-clay nanocomposites, and articles or products produced from nanocomposite materials.

Abstract: This invention is directed to a polymer-clay nanocomposite, products produced from the nanocomposite, and a process for preparing a polymer-clay nanocomposite. The polymer-clay nanocomposite comprises (a) a matrix polymer, (b) an amorphous oligomer, and (c) a layered clay material.

Abstract: This invention relates to a process for preparing an amorphous polyamide-clay nanocomposite comprising the steps of: a. melt mixing a layered clay material with an oligomeric polyamide resin to form an oligomeric polyamide resin-clay composite, and b.

Abstract: This invention relates to a composite composition comprising one or more polyamide polymers or copolymers, one or more layered clay materials, and one or more alkoxylated ammonium cations. The invention also relates to a process for preparing a nanocomposite and articles produced from the nanocomposite, including bottles.

Abstract: A method of forming bricks, tiles, and the like by treating clay, shale or other clay ceramic raw materials containing pyrite is disclosed. Such clay, ceramic raw materials may be ground, and then mixed with an oxidizer in a pre-oxidation step to disperse the oxidizer within the clay to expose the maximum amount of clay surface to the oxidizer. One oxidizer that may be used is an aqueous solution of hydrogen peroxide. Clay is shaped into clay products and then heated to elevated temperatures. Pyrite within the clay is oxidized, thereby removing sulfur-containing compounds such as sulfur dioxide from the clay. The application of the invention may assist in preventing efflorescense by ensuring complete or nearly complete removal of pyrite from products oxidation treatment and subsequent firing at elevated temperatures. Similarly, by enhancing the oxidation of pyrite, faster firing cycles may be possible which facilitates reduced fuel consumption and faster process time.

Abstract: Processes for modifying the surface chemistry of a clay are disclosed. In one embodiment, there is provided a process for modifying the surface chemistry of a clay, wherein the process comprises: providing a clay dispersion comprising at least one unmodified clay wherein said clay has a first exchangeable cation; adding a second cation to the clay dispersion, wherein at least a portion of the second cation exchanges with at least a portion of the first cation to form a modified clay dispersion; and combining at least one polar containing agent with the modified clay dispersion to provide a modified clay.

Abstract: A waterproofing material free of loose particulate material comprising a waterproofing sheet formed by extrusion under vacuum from a substantially homogeneous, deformable mass consisting of a mixture of particulate smectite clay and liquid.

Abstract: A process of making ceramic spheroids by firing clay spheroids comprising by weight percent: FeO (3.22-5.21), Fe3O4 (3.40-5.11), SiO2 (52.49-59.42), CaO (1.99-7.96), MgO (2.81-4.69), Al2O3 (12.05-17.65), TlO2 (0.58-0.71), MnO (0.07-0.19), Na2O (0.47-0.86), K2O (1.70-2.37), P2O3 (0.13-0.19), S (0.03-0.29), CO2 (0.90-8.23), Organic C (0.22-1.04), H2O+ (4.14-7.28), H2O− (2.12-5.48) in contact with a particulate parting agent selected from aluminum oxide, magnesium oxide, and their precursors at a sufficiently high temperature and for a sufficiently long time to form a shell. Preferably, the clay spheroids are obtained from a deposit located at Hallock in Kittson County Minn., U.S.A.

Abstract: A method for preparing organoclays from smectites for use as rheological control agents and in the preparation of nanocomposites. Typically, the clay is dispersed in water, and a substantially monomolecular layer of a water soluble polymer is applied to the surfaces of the clay. A surfactant is also applied to the clay to modify the surface hydrophilic/hydrophobic balance of the clay, and the organoclay is separated out for subsequent use.

Abstract: A method of forming bricks, tiles, and the like by treating clay, shale or other clay ceramic raw materials containing pyrite is disclosed. Such clay ceramic raw materials may be ground, and then mixed with an oxidizer in a pre-oxidation step to disperse the oxidizer within the clay to expose the maximum amount of clay surface to the oxidizer. One oxidizer that may be used is an aqueous solution of hydrogen peroxide. Clay is shaped into clay products and then heated to elevated temperatures. Pyrite within the clay is oxidized, thereby removing sulfur-containing compounds such as sulfur dioxide from the clay. The application of the invention may assist in preventing efflorescense by ensuring complete or nearly complete removal of pyrite from products oxidation treatment and subsequent firing at elevated temperatures. Similarly, by enhancing the oxidation of pyrite, faster firing cycles may be possible which facilitates reduced fuel consumption and faster process time.

Abstract: Disclosed is clay material, the particles of which are intercalated with a compound comprising a saturated isoprene oligomer bonded to a polar group. In a preferred embodiment the polar group is a quaternary ammonium radical. Further disclosed is a nanocomposite comprising C2-C3 &agr;-olefin polymer material, and, dispersed in the matrix of the olefin polymer material, exfoliated clay material, the particles of which before exfoliation were intercalated with said compound.

Abstract: Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer having a hydroxyl and/or an aromatic ring functionality to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 Å (as measured after water removal to a maximum of 5% by weight water), up to about 100 Å and preferably in the range of about 10-45 Å, so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix.

Abstract: This invention discloses novel water-responsive compositions with improved stability to aqueous liquids and an improved method of making the compositions. The addition of organically modified clay to poly(ethylene oxide) significant improves the liquid stability and melt processability of the PEO. The PEO compositions can be produced using an economical one step process comprising blending a dry mixture of PEO and organically modified clay particles and melt processing the dry mixture. The melt processing of a mixture of PEO and organically modified clay particles facilitates the melt processing of PEO over a broad range of molecular weights, most notably high molecular weights. Advantageously, the process described herein eliminates expensive and complex processing steps and is useful for manufacturing flushable articles such as disposable diapers, feminine pads, pantiliners, etc.

Abstract: A method for producing an Attapulgite clay (Fuller's Earth) that significantly removes other types of clays and minerals, resulting in improved performance. A unique dispersant is used that will fully disperse the individual Attapulgite particles in water such that the particles remain in suspension, and allow the non-Attapulgite clay particles to be liberated, which then can be easily separated through various techniques. The Attapulgite clay may be recovered from the dispersion and dried in such a manner to produce a finely sized powder from ore, without the need for any grinding or milling operation. The dried Attapulgite clay has a free moisture content of 2-3%. The dried Attapulgite clay with adsorbed dispersant is redispersed in water and retains thixotropic properties.

Abstract: This invention is directed to a polyamide-clay nanocomposite, products produced from the nanocomposite, and a process for preparing a polyamide-clay nanocomposite. The polyamide-clay nanocomposite comprises (a) an amorphous matrix polyamide comprising (i) a residue of a dicarboxylic acid component comprising at least two diacids and (ii) a residue of a diamine component, and (b) a layered clay material, wherein the layered clay material is dispersed in the matrix polyamide.

Abstract: Hybrid layered silicates with galleries between the layers containing both inorganic and organic ions with different compositions in different galleries are described. The resulting hybrid layered silicates provide economical starting materials for polymers and the like.

Abstract: Intercalated layered materials prepared by co-intercalation of a multi-charged onium ion spacing/coupling agent and a matrix polymer between the planar layers of a swellable layered material, such as a phyllosilicate, preferably a smectite clay. The spacing of adjacent layers of the layered materials is expanded at least about 3 Å, preferably at least about 5 Å, usually to about 15-20 Å, e.g., 18 Å with the di-charged onium ion spacing/coupling agent. The intercalation of the matrix polymer then increases the spacing between adjacent layers to at least about 15 Å, preferably to about 20 Å to about 30 Å.

Abstract: This invention relates to a polymer-clay nanocomposite having an improved gas permeability comprising (i) a melt-processible matrix polymer, and incorporated therein (ii) a layered clay material intercalated with a mixture of at least two organic cations. The invention also relates to processes for preparing a nanocomposite and articles produced from a nanocomposite.